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Robin America RGX180 Service Manual

Robin generator service manual
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Mot~ti' RG
RGX240,
issu E
EMU - GS0068
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Summary of Contents for Robin America RGX180

  • Page 1 -Rain Mot~ti’ RG RGX240, issu E EMU - GS0068...

  • Page 2: Table Of Contents

    1. SPECIFICATIONS 2. PERFORMANCE Model RGX180 Model RGX240 Model RGX240D DC OUTPUT (RGX240, 3. FEATURES 4. GENERAL DESCRIPTION of GENERATOR 4- 1 External View of Generator RGX180 Panel ... RGX240 Panel ... RGX240D Panel. 5. CONSTRUCTION and FUNCTION 5- 1...

  • Page 3: Specifications

    RGX180 50H7 15oow 13oow 1lOV 11.8A 22ov 5.9A 23OV b.7A 24OV 5.4A Not avir~lablu Max. Output Fuel F WI Tank Caf,ac~ ly Oil Capacity Rt?vnltl I lonlmln Ignltlon SVSIWTl Stwtlrlg SystRlrl Fuel Consumption Ratio 1 .l Iltcl /Hr (5OHrj...

  • Page 4: Performance

    PERFORMANCE MODEL RGX180 Type _ ..Self-Exciting. Power Factor ..1.0 Engine ...

  • Page 5: Model Rgx240

    MODEL RGX240 Type Self-Exciting, Power Factor Engine EY20D CURRENT ’ PJ 210 123456789 CURRENT7 VC%TAGE 240- ‘23456789 CURRENT(A) 2-Pole, Single Phase “(Wl-185) Output - 2000 ‘150 Frequency. Voltage ‘1000 Output 2000 Frequency. Voltage. Output .. 2000 -1 500 Frequency Voltage 1000 NOTE: These characteristics...

  • Page 6: Model Rgx240D

    MODEL RGX240D Self-Exciting, Type Power Factor 1 .O Engine EY20D ‘(Wl-185) I i I CURRENT (A)- (Al - CURRENT 2-Pole, Single Phase Output Max. Rated 1500 Frequency. .-1000 Voltage ..Output Max. Rated Frequency .

  • Page 7: Dc Output

    DC OUTPUT (RGX240, RGX24OD) CURRENT If the generator is connected to a battery to charge it, its DC output voltage increases. The battery is charged at the increased voltage level. Performance curve @ applies to a case under a resistance load only; and curve @ represents battery charging characteristics.

  • Page 8: Features

    FEATURES Lightweight, Compact The Robin engine and revolving field generator designs provide added output poxer per weight and economical opera- tion. Centralized Control The witches. meters. and receptacles located on top of the engine for eas)- generator operation. Large IO-Liter Gas Tank *IO-liter (2.6 LT.S.
  • Page 9 Easy Starting with Recoil Starter 13. Circuit Breaker for Troublefree Operation 14. Ruggedly Built Frame The box type frame is so ruggedly built that two or more generators can be stacked. Another convenient feature of the Robin generators. 15. A Caster Type is Optionally Available.

  • Page 10: General Description Of Generator

    SPEED CONTROL LEVEH FUEL GAUGE imd TANK CONTI301. CHOKE KNOB STOP BUTTON FUEL TANK SPARK PLUG GAUGE , , .I,’ GENEHATOR FlJEl S~~-~AINEH HUBBEH MOUNT I-iECOlL STARTEt7 tiANDLE AlI{ CLEANLIt MUFFLEt FlJEI COCK...

  • Page 11: Rgx180 Panel

    RGX180 PANEL 4-2-l 1 lOV, 120V CIRCUIT BREAKER AC RECEPTACLE EARTH (GROUNDI 4-2-2 220V. 23OV, 240V CIRCUIT BREAKER AC RECEPTACLE EARTH fGROIJNDl ‘dc TERMIN/AL TERMINAL _- 9 - /../- NEON LAMP “. FUEL COCK ! ‘k.. FiJEL STRAINER NEON LAMP...

  • Page 12: Rgx240 Panel

    RGX240 PANEL 4-3-l 1 lOV, 120v CIRCUIT BREAKER AC RECEPTACLE EARTH !GROUNDI TERMINAL 4-3-2 22OV. 23OV, 240V CIRCUIT BREAKER AC RECEPTACLE EARTH (GROUND1 TERMINA; i ;/ /’ ,,‘. ,’ -10- VOLTMETER DC FUSE DC OUTPUT TERMINAL .LOPEN, FUEL COCK FUEL STRAINER VOLTMETER DC FUSE...

  • Page 13: Rgx240D Panel

    RGX240D PANEL 4-4-l llOV,‘22OV, 12OV,‘24OV AC REC’IPTACLE -! , CIRCUIT BREAKER/ AC RECEPTACLE EARTH IGROUND) CIRCUIT BREAKER I ON OFF FUSE iOA TERMINAL’ -11- VOLTMETER DC FUSE OUTPUT TERMINAL FUEL COCK FUEL STRAINER...

  • Page 14: Construction And Function

    STATOR COMPL. ROTOR COMPL. THROUGH.BOLT FRONT COVER SHAFT SLIP RING COVER BOLT ENGINE P.i.0. SHAFT RUBB’ER MOUNT RDTOd COMPL. BRUSH HOLDER REAR COVER STATOR COMPL. COOLING...

  • Page 15: Functions

    FUNCTIONS 5-2-l STATOR The stator consists of a laminated silicon steel sheet core, copper wire which winds the core, and lead wires which de- liver the power. The copper wire is wound into the main coil. sub (.ausiliary) coil, and DC coil. XC output power is taken from the main coil.
  • Page 16 (DC) to the field coil turns the rotor and magnet. The cooling fans cool the generator by drawing cooling air from the slip rings and dis- charging it through the fans. Fig. 5-4 MODEL RGX180 (mm) 99.6 (In.) 3.92 (mm) 2.36...
  • Page 17 5-2-3 BRUSHES An exciting current is supplied from the AVR to the rotor. The brushes are made of carbon, and the brush-holders of plastic. It is necessary to keep the contact pressure between the brushes and slip rings within specitic limits. Thus. care must be taken about brush length.
  • Page 18 5-2-6 CIRCUIT BREAKERS Models RGX180 and RGX240 have a pushbutton circuit breaker and Model RGX240D two pushbutton circuit breakers. Nomrallp, the pushbutton circuit breaker is closed with the button pushed into the panel to keep the circuit live. If an overcurrent runs. the button comes out to break the circuit.
  • Page 19 5-2-7 FUSE The fuse prevents DC output overcurrent and short<ircuir overcurrent. Ii the generator is operated at a level exceeding the maximum current. it can cause insulation deterioration. ‘curninp. electric shock. and electric leakage. The fuse protects the generator from these troubles. 5-2-8 RECEPTACLE and AC PLUGS...
  • Page 20 Rubber pads for controlling generator vibration and disloca- tion. These are made of the most suitable rubber material to optimum shape and hardness. Models RGX180. RGX240. and RGXI4OD in particular use diagonal support rubbers to reduce vibration. 5-2-13 PIPE FRAME The pipe frame consists of a pipe frame skeleton.

  • Page 21: Description Of Generator Operation

    DESCRIPTION of GENERATOR 5-3-l REVOLVING ARMATURE TYPE and REVOLVING NO-FUSE .<‘G ---+--- POLE ASSY -FIELD SHAFT / ARMATURE ASSY ROTOR COMPL. BRUSH HOLDER OPERATION FIELD TYPE CONTROL AC VOLTMETER BREAKER ‘... COIL J!-kFT&f~- ‘zzz, ;)’ FIELD COIL ’ RUBBER VIBRATION Fig.
  • Page 22 The RG Series 1s the revolving armature type. and the RGX Series is the revolving field tk-pe. The differences between these types and then features are described below. The constructron of the revolving armature t>-pe is shoxn in Fig. 5 -15. and that of the revolvmg field type in Fig.
  • Page 23 5-3-2 PRIMARY EXCITING ACTION The RGX Series employs an exciting coil in the engine mag- neto for raising the primary voltage. This action is explain- ed. The RG Series generates a voltag2 when the generator IS started again because of the residual magnetism remaintng in the yokes and poles.

  • Page 24: Change Of Engine Parts

    5-3-4 DUAL VOLTAGE TYPE (RGX240D) The dual voltage t)-pe can generate two Foltages from a sin- gle generator. It comes in two varieties: 12OV~‘11OV and 1 lOV!ZOV. The circuit is shown in Fig. 5-l 8. Each of MC1 and MC2 generates an AC 12OV (or 1lOV) with same phase, which is one half the rated output voltage.
  • Page 25 5-4-2 CONTROL SYSTEM The control parts are certainly located to permit centralized control at the top of the engine. The parts added or changed are as shown in Fig. 5 -20. CONTROL SPRIVG WASHER GOVERNOR LEVER Fig. 5-20 -23- PANEL CP.
  • Page 26 5-4-3 FUEL SYSTEM The large-sized IO-liter fuel tank is mounted in the frame. The fuel piping was changed as a result as shown in Fig. 5-Z 1. 5-4-4 COOLING SYSTEM -4 baffle is provided to prevent engine cooling air from rais- ing the temperature of otherparrs.
  • Page 27 5-4-5 CARBURETOR The carburetor has an air vent and a rubber pipe to ensire stabilized performance at high temperature. 5-4-6 OTHERS The air cleaner and muffler were modified in shape, but are installed in the same way as before. The air cleaner element is the same as the one used in the cyclone type.

  • Page 28: Safety Precautions

    SAFETY PRECAUTIONS 1. Use extreme caution near gasoline. A constant danger of explosion or fire exists. Do not fill the fuel tank with gasolin u-hi12 the engin is runmng. Do not smoke or use open tlame near the fuzl tank. car2ful not to spill fuel when refuueling.

  • Page 29: Range Of Applications

    RANGE of APPLICATIONS Generally. the rat2d power of an electrical apphan<e oiten refers to the amount oi work that can be don2 b?- it. The electric power required t?r operating an electrical apphance is not necessarily produ~rs generally ha\2 a lsb2L showing their ra ted voltage. irrequeniy. and polver consumption (input power!. The Eiectri4 polv2r consumption of an 2lectrical product is the power newssark for using it.
  • Page 30 Motor-driven tool, general-purpose motor, etc. Water pump, compressor = (Power consumption) 0.6 - 0.75 - The smaller the capacity. the wors2 the efficiency. and dce versa. RGX180 50Hz ’ 60Hz 50Hz 1300w 15oow 1700~ about about about 850W...
  • Page 31 NOTE: Wiring between generator and electrical Allowable current of cable cable with a allowable current input current is higher than the allowable teriorate the insulation, possibly Cable length If a long cable is used, a voltage drop occurs due to the increased to the load (electrical produc t) decreases.

  • Page 32: Measuring Procedure

    MEASURING PROCEDURE METERS 8-l-l VOLTMETERS XC and DC vo!tmeters are necessary. The approximate XC voltage ranges of the voltmetsrs to be used for various types of g2nerators are as follows: 0 to 150\-: Type with an output voltage of I 10 or 13OV 0 to 3OOV: Tl-pe with an output voltage of X0.
  • Page 33 8-l-4 TESTER Used for measuring resistance, etc. 8-l-5 MEGGER TESTER Used for measurmg generator insulation resistance. Select one lvith testing voltage range of SOOk-. 8-l -6 TACHOMETER There are various types of tachometers. such as contactless type. contact and strobe type. The contact type can :ype.
  • Page 34 AC OUTPUT MEASURING TOACd/LE+@ Use a circuit like the one shown in Fig. 8-7 for measuring XC output. A hot plate or lamp Lvith a power factor of 1 .O ma>- be used as a load. Adjust the load and rpm. and check that the voltage range 1s as and rated rpm 1lOV Rated voltage...
  • Page 35 STATOR Measure the insulation resistance between the red or white coupler from the stator and the core. . ROTOR Measure the insulation resistance between the core and one of the slip rings of the rotor. . CONTROL Measure the msulation between the live parts and the casing or grounded part.

  • Page 36: Checking Functional Members

    CHECKING FUNCTIONAL STATOR ASSEMBLY 9-l-l MEASURING WINDING RESISTANCE Check the resistances of the leads from the stator Lvith a tester (See Fig. o - 1.) Check leads \\hich are shown b>- all the belc?w- An> !ead which IS mxtive is fault)-. NOTE: Testers are not so accurate that some margin...

  • Page 37: Rotor Assembly

    OVi22OV. 50Hz 12OVf24OV Wire color WHITE ’ 1.15Q 1 lou;22ou. 12oui24ou 60Hz 9-l-2 MEASURING INSULATION Refer to 8-4 MEASURING INSULATION ROTOR ASSEMBLY 9-2-l WI-NDING RESISTANCE MEASURING Check the resistance between the two slip rings with a test- er. (See Fig. 9-2.) The resistance is normal if it is an>vhere from 6 ohms to 13 ohms.

  • Page 38: Brushes

    BRUSHES The brushes must be smooth where they contact the slip rings. If not. polish the brushes smooth with sandpaper. X brush that is not smooth produces arcs between the brush and slip ring leading to possible damage. Usable brush lengths are from 5mm to ljmm as shown in Fig.
  • Page 39 MODEL RGX305, RGX305D Tester polarity Yellow Yellow White Green Brown *Upper rows are for the 220, 230, 240U specifications; and the dual voltage type. 9-4-3 IDENTIFYING TROUBLE SCR or transistor damage cannot be detected by simply looking at the AVR or checking the lead resistances. Check it by mounting the suspectedly faulty AVR in a normal generator, or mount a normal AVR in a generator which fails to generate voltage.

  • Page 40: Fuse Holder And Circuit Breaker

    FUSE HOLDER and CIRCUIT 9-5-l CIRCUIT BREAKER Push the power switch on and check continuity. If current flows, it is normal. Devices such as that shown in Fig. 92 are necessary for checking the circuit breaker if it properly operates. The rated current is shown on the side of the circuit breaker.

  • Page 41: Receptacle And Ac Plug

    RECEPTACLE and AC PLUG Check the current-carrying parts of the receptacles and AC plugs and their leads and plastic parts for burns. VOLTMETERS and PILOT LAMP Apply AC voltage to a terminal and check if the voltmeter reads normal or pilot lamp lightens. DIODE STACK ASSEMBLY Fig.

  • Page 42: Primary Exciting Circuit

    PRIMARY EXCITING CIRCUIT As described m 5-3 DESCRIPTION the primary exiting coil is in the magneto ERATION. mounted on the engine. and the AVR has a circuit for it. 9-9-l EXCITING COIL The normal inter-terminal reststance of the exciting coil is about 10 to 30 ohms.

  • Page 43: Disassembly And Reassembly

    DISASSEMBLY and REASSEMBLY 10-I PREPARATIONS and SUGGESTIONS When disassembling the engine ~ remember the locaticns of individual you are uncertain of identify-ing some parts, it is suggested that tags be attached to them. Have boxes ready to keep disassembled parts in groups. prevent losing or misplacin,.
  • Page 44 Fig. 1 O-3 Order ’ Item / Control Box ( 1 I Remove the grommet from the rear of the control box. 1 (2) Pull out the conmxtor box. and take it ofi. PULL (3) Remove the coupler that is connected to the rear of the control box.
  • Page 45 Fig. 10-6 Item Order -’ Frame I. 1) Remove ths box sTa)-. 6~ bolt ( 2, Remove ths side platss. front and rear. I See Fig. 10-8.~ 60 bolt ! ! 3) Rzmovs th2 g2nsrator mounting nuts. Remove the nuts that fast22 ths sngine and rubber mount and the nuts that fastsn the gsnsrator and rgjber 8g nut...
  • Page 46 1 Order item Brush holder ( 1) Remove the brush cover. Remove the brush cover in the back of the rear cover. 40 screw I (2) Remove the brush holders. (See Fig. 10-10.) Disconnect the terminals wired to the brushes before removing the brush holders.
  • Page 47 Order Item Stator i 1) Remove the stator. Puil out the stator from the front cover by lightly tapping the outside of the core with a plastic hammer. (See Fig. lo- ’ stator steel sheets. 11.) If the stator does not come out. insert a screwdrive betaeen the front cover and stator.
  • Page 48 Order / item Rotor ( 11 Pull out the through-bolt. spanner or socket wrench orer the head of the through-bolt. hard <ounterclockwse mer to loosen. and remove the through-bolt. 100 bo:t . . 1 pze. I.2) Remove the rotor. Strike the rotor by the core with a plas- ! or windings. tic hammer.

  • Page 49: How To Reassemble

    NOTE: The outside diameter ness of the rotor is shown in 5-2-2 5-2 FUNCTIONS. Paragraph NOTE: The through-bolt is shaped as shown RGX180 RGX240 RGX240D air are down. and lamination thick- ROTOR under below. Model ’ 222 mm ’...
  • Page 50 10-3-3 STATOR Install the stator to tit the faucet joint of the front cwer. If it does not fit properly. lightl>- strike the stator cnre \vltil a plasti, _ hammer as shown in Fig. 1 O-19. NOTE: Never strike the winding. NOTE: Make sure that the wires to the control :cj BRUiti...
  • Page 51 The bushing has a larger diameter than the grommet. the wires between unless the front cover and rear cover are positioned below. Model RGX180 RGX240 RGX240D - 49 - Fig. lo-22 correctly. 90mm ’...
  • Page 52 Insert the wires into the connectors. The connrctor positions and wtr2 colors are shown in Table 10-J. NOTES: Terminals through ‘z; and cj, c$ij for 0.75 mm’ wire. ::z / 12; ’ .zj ! RGX180 RGX240 WHITE RGX240D BLACK WHITE 10-3-5 BRUSH hOLDER 1) Install the brtish holders in the rear cover.
  • Page 53 2 I Attach the connector to the brush holder. Connect the green lead to the stator side and the brown lead to the bearing side. Install the brush cover. 49 x 10 mm screw . . 3 pcs. 10-3-6 FRAME 1 I The frame has holes for the rubber mount locks.
  • Page 54 2> Install the generator in the frame. Lift the generator with a chain b!ock. install it in the Dame. and tighten the nuts. (See Fig. 10-29.) 8Qnuts. . _ ..4pcs. SQ washers ..-I pcs. spring washers .
  • Page 55 3) Connect the connectors to the control box. And push the connectors into the control box. Install the bushing on the control box. NOTE: No clearance is allowed and bushing. (See Fig. 10-32.) 10-3-8 FUEL TANK 1) Connect the rubber pipe to the engine carburetor and fasten it with the hose clamp. Attach the banjo to the opposite end of the rubber pipe.
  • Page 56 FUEL GAUGE RUBBER PIPE STRAINER BRACKET BANJO BANJO BOLT BOLT FUEL TANK ’ - HOSE CLAMP RUBBER HOSE CLAMP FUEL STRAINER Fig. lo-33 - 54 - PIPE...

  • Page 57: Control Box Check, Disassembly, And Reassembly

    10-4 CONTROL BOX CHECK, DISASSEMBLY, 10-4-l CHECK Check the wiring bp removing the control box from frame and taking the panel B (rear panel) off, 10-4-2 DISASSEMBLY 1) Remove the control box panel B (.rear panel) and the front panel from the control box. (See Fig. 10-34.) 2) Remove the connectors from the control box, and the wires from the connectors.

  • Page 58: Trouble-Shooting

    TROUBLE-SHOOTING When rhe generator is in trouble. carefully check the trouble and remed)- IL Voltmeter does not work or pilot lamp does not light. Primary 7 OK > Wrong wiring or some leads unconnected Resistance outsrde range of 5 --7.5R qy-Eq (Check winding...
  • Page 59 &+x+ Characteristics Check AVR (Cause) See (1) Voltmeter Fuse burnt Wrong wiring Diode broken faulty DC coil broken Rpm unadjusted broken - 57 - (Remedy) does not work. . Check for cause and replace. Wire correctly. Replace. Replace stator. Replace ctator.
  • Page 60 (4) ( Voltage too low If AC voltage Wiring checked? is less than 1OV. voltmeter needle should not deflect. loose wire joints than ----+ - 58 - (Remedy) Uhusel Rpm unadjusted Adjust. Wire correctly. Wrong wiring Adjust. Replace rotor. Field coil shorted Clean, replace.
  • Page 61 ’ Off-load voltage is normal, but load cannot be L__1 EngIn? output power I---- Ins4ft,cienr AC plug crecked for shortcl-cult! ‘IsI Resistance infinite : Net cnecked properly. Or, opera- ;lon returns to norm21 byhen AVR is replaced with anorhe: one. See Englne Trouble-shoo:lng -- 59 -...

  • Page 62: Options

    OPTIONS 12-l CASTER 1) The caster base IS fitted with rubber casters 5Omm in diameter and the caster base 1s bolted to rhe frame. 2) The frame has threaded holes for mounting the caster bases. BOLT6~~15...16pcs. BOLT6ox15... : ,;’ /’ WASHER NUT 60.

  • Page 63: Circuit Diagram

    CIRCUIT DIAGRAM MODEL RGX240 GENERATOR UHANti (RED ---- MODEL RGX240D GENERATOR ----I BLUE ---I CONTFOL -CB- WHITE YELLOW YELLOW CONTROL ----Gil- YELLOW YELLOW -~-- ENGINE ’ DC OUT ENGINE -...-. lT.I.C.1 DC OUT i I I--...
  • Page 64 MODEL RGXIBO GENERATOR . SYMBOLS I ~~ Symbols Name of Parts AC Winding Auxiliary Winding DC Winding Field Winding Brush Automatic Voltmeter Pilot Lamp Diode Stack Assy Earth (Ground) Fuse CONTROL Symbols RECl Voltage Regulator S.I.U. Terminal - 62 - ENGINE Name of Parts Receptacle...

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Rgx240Rgx240d

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